HDPE drainage€¦ · This guide contains product specification ... 16 HDPE installation 17...

1MARLEY HDPE |

HDPE drainage

marleypd.co.uk

MARLEY HDPE |

Marley HDPE

Marley HDPE is a drainage system which offers an

alternative solution to cast iron. It is particularly suited

for commercial applications or where a product with

high impact or abrasion resistance is required, such as

hospitals, hotels, schools, as well as residential buildings.

HDPE is certified to BS EN 1519. HDPE will also cope with

temperature variations of -40°C to 100°C making it ideal

for external as well as internal installations.

Innovation & Expertise

This guide contains product specification details, design and installation information for The Marley HDPE range.

Information on the complete range of Marley Plumbing and Drainage system solutions is available to download from marleypd.co.uk or via the literature hotline 01622 852585.

FM 30637 KM 545820

4 Marley Soil & waste systems

6 HDPE drainage

Installation 16 HDPE installation

17 Compatibility

18 HDPE jointing methods

24 HDPE bracketing

27 HDPE handling and storage

28 British and European standards

29 Marley system solutions

Contents

3

EMS 96207BS EN 1519

5MARLEY HDPE |4 | MARLEY HDPE

The Marley HDPE drainage range is certified to BS EN 1519: 2000 (licence number KM 545820) An extension of the Marley soil & waste portfolio, the HDPE range offers an alternative solution to cast iron.

The combination of the excellent material properties of HDPE with homogenous welded joints provides greater installation flexibility with a wide range of jointing options.

Key fitting: Akavent AeratorThe need for secondary venting in high-rise buildings can be eliminated with the Akavent aerator. An Akavent aerator fitting breaks the discharge fall on each floor and as a consequence the secondary vent pipe is not required as the pressure difference stays well within the limit of 3 mbar.

The unique shape of the fitting increases the capacity of the stack allowing the soil and waste flow from the higher floors to smoothly converge with the flow on the lower floor.

Marley soil & waste systems

Solvent waste Push-fit waste Overflow Compression waste Traps

PVCu ABS Polypropylene PVCu Polypropylene Polypropylene

Suitable for internal and external applications.

Lightweight and cost effective for internal installation. Easy to cut joint and install.

For internal use, ideally suited to fast installation. Cost effective solution where systems are being installed or modified.

A complete range of pipework and fittings for overflow and boiler condensate applications.

Multi-fit compression socket, for internal use. Easy installation to similar sized new or existing plastic and copper pipework.

A range of traps, which enable quick & easy installation to any new or existing plastic or copper pipework.

Available in 32, 40 and 50 mm


Available in 32, 40 mm

Available in 21.5 mm

Available in 32, 40 mm


White & Black White, Black & Grey White, Black & Grey White White & Chrome White & Chrome

82, 110 and 160mm push-fit and solvent weld soil systems incorporating socketed and plain ended pipe

110 and 160mm pipe support components designed specifically to meet the needs of supporting horizontal or vertical suspended PVCu pipework.

82, 110 and 160mm pipes and fittings are also suitable for use as internal and external rainwater pipes to drain flat roofs and metal gutter systems on commercial and industrial buildings.

The range includes the 8-way soil manifold which offers the flexibility of 4 top and 4 side entries, allowing for multiple inlet connections.

ABS and polypropylene waste pipes and fittings are designed for internal use and should not be fitted externally as they will be subject to ultraviolet light degradation. If fitted externally it is recommended that they are protected by the application of a suitable paint or are boxed in.

Technical advisory serviceTechnical Services offer a free advisory service, providing technical assistance regarding product and installation details. Those involved with the building industry may take advantage of design services provided by the company for customers who have made a commitment to use or specify Marley products.

Technical Hotline: 01622 852695UFC1

S411195S421150

SVD4KT2

KAP2

KAP2

2No KR210

S201156S411195GW059

40mm

110mm

110mm

WCSBS40MKS2

WCSBS40MKS2

WHBB032R

WHBB032R

S2411034No S411195

2No S1211453No S411195

KBA22KB22

KXT21

Marley PVC Soil

Marley waste

Marley HDPE

An acoustic soil and waste range with a layered pipe providing quick, hygienic removal of sanitary waste water. The noise generated by the flow of water is dramatically reduced – making it perfect for multi-occupancy apartment blocks and high specification developments.

Marley acoustic system

76 | MARLEY HDPE MARLEY HDPE |

BEND 90° – SHORT d

1Code l

1 r Qty d

1Code l

1 r Qty

160 S 11 16 91 160 160 10 250 S 11 25 91 290 265 1

200 S 11 20 91 205 200 10 315 S 11 31 91 340 300 1

Butt-weld only

BEND 90° – LONGd

1Code l

1l2

r k1 Qty d

1Code l

1l2

r k1 Qty

56 S 11 56 92 120 59 56 55 20 110 S 11 11 92 180 113 110 60 20

75 S 11 07 92 140 78 75 60 25

Electrofusable at one side

BEND 15° d

1Code l

1r k

1 Qty d

1Code l

1r k

1 Qty

110 S 18 11 15 125 165 65 1 250 S 18 25 15 225 375 135 1

160 S 18 16 15 175 240 100 1 315 S 18 31 15 250 473 175 1

200 S 18 20 15 200 300 125 1

Fabricated

BEND 30° d

1Code l

1r k

1 Qty d

1Code l

1r k

1 Qty

110 S 18 11 30 125 165 60 1 250 S 18 25 30 225 255 125 1

160 S 18 16 30 175 240 100 1 315 S 18 31 30 250 320 135 1

200 S 18 20 30 200 200 115 1

Fabricated

Available in black only.

PIPE

d1

Code e cm2 Qty d1

Code e cm2 Qty

56 S 10 56 00 3.0 19.60 149 200 S 10 20 00 6.2 276.41 20

75 S 10 07 00 3.0 37.40 81 250 S 10 25 00 7.7 431.52 12

110 S 10 11 00 4.2 80.70 75 315 S 10 31 00 9.7 685.35 10

160 S 10 16 00 6.2 171.10 39

cm2 = cross sectional area of flow Pipe = Tempered

ELECTROFUSION COUPLERd

1Code D L System Qty d

1Code D L System Qty

56 S 41 56 95 68 54 5A/80s 20 200 S 41 20 65 233 175 220V/420s 1

75 S 41 07 95 87 54 5A/80s 20 250 S 41 25 65 283 175 220V/420s 1

110 S 41 11 95 122 58 5A/80s 20 315 S 41 31 65 349 175 220V/420s 1

160 S 41 16 95 172 66 5A/80s 5

EXPANSION SOCKET

Type A Type B

d1

Code D d L Qty d1

Code D d L I1

Qty

75 S 42 07 20 * 100 76 256 20 56 S 40 56 20 * 74 57 172 135 20

110 S 42 11 20 * 137 112 256 20 200 S 40 20 20 ** 230 202 460 230 1

160 S 42 16 20 * 189 162 256 5 250 S 40 25 20 ** 300 253 480 250 1

315 S 40 31 20 ** 370 319 510 270 1

Seals: SBR * Includes protection plug ** Excludes protection plug See page 26 for details on TYPE A / TYPE B

PLUG-IN SOCKETd

1Code D d L I

1Qty d

1Code D d L I

1Qty

56 S 42 56 50 72 57 89 54 20 110 S 42 11 50 131 111 111 69 20

75 S 42 07 50 96 76 109 69 20 160 S 42 16 50 190 162 147 105 10

Electrofusable spigot ends Seals: SBR

Includes protection plug

INSPECTION SCREWd

1Code D L Qty d

1Code D L Qty

56 S 66 56 40 81 74 20 110 S 66 11 40 145 106 10

75 S 66 07 40 111 106 20

PIPE LENGTH = 5 M

PIPE LENGTH = 3M

3575

To BS EN 1519 as appropriate. Available in black only.

d1

Code e cm2 Qty

110 S 10 11 03 4.2 80.70 48

HDPE drainage


d1/

d2

Code L l1/l

2l3

k1

k2

k3

Qty

56/56 S 30 56 56 180 120 60 25 25 40 20

75/56 S 30 07 56 210 140 70 35 25 55 20

75/75 S 30 07 07 210 140 70 25 25 40 20

110/56 S 30 11 56 270 180 90 45 40 90 10

110/75 S 30 11 07 270 180 90 35 30 75 10

110/110 S 30 11 11 270 180 90 20 20 55 15

160/56 S 30 16 56 * 375 250 125 120 115 65 5

160/75 S 30 16 07 375 250 125 120 115 65 5

160/110 S 30 16 11 375 250 125 50 40 45 5

160/160 S 30 16 16 375 250 125 10 15 25 5

200/75 S 30 20 07 540 360 180 95 160 175 1

200/110 S 30 20 11 540 360 180 65 140 150 1

d1/

d2

Code L l1/l

2l3

k1

k2

k3

Qty

200/160 S 30 20 16 540 360 180 35 85 115 1

200/200 S 30 20 20 700 430 270 160 160 230 1

250/110 S 30 25 11 * 660 440 220 150 185 215 1

250/160 S 30 25 16 * 660 440 220 120 130 180 1

250/200 S 30 25 20 * 660 440 220 90 50 150 1

250/250 S 30 25 25 * 900 600 300 160 160 250 1

315/110 S 30 31 11 * 840 560 280 235 260 305 1

315/160 S 30 31 16 * 840 560 280 200 205 270 1

315/200 S 30 31 20 * 840 560 280 175 125 240 1

315/250 S 30 31 25 * 840 560 280 140 130 205 1

315/315 S 30 31 31 * 950 610 340 170 170 280 1

* Fabricated

BRANCH 45º


ELBOW 88.5° d

1Code l

1k

1Qty d

1Code l

1k

1Qty

56 S 12 56 88 65 20 20 200 S 12 20 88* 290 60 1

75 S 12 07 88 75 20 20 250 S 12 25 88* 350 60 1

110 S 12 11 88 95 25 20 315 S 12 31 88* 360 60 1

160 S 12 16 88 120 25 10

* Fabricated

ELBOW 45° – SHORT d

1Code l

1k

1Qty d

1Code l

1k

1Qty

56 S 12 56 45 45 20 20 200 S 12 20 45 173 60 5

75 S 12 07 45 50 20 20 250 S 12 25 45 182 60 5

110 S 12 11 45 60 25 20 315 S 12 31 45 195 60 5

160 S 12 16 45 69 20 5

ELBOW 45° – LONGd

1Code l

1l2

Qty

75 S 12 07 46 145 50 20

110 S 12 11 46 155 60 20

Elbows 45° with long spigot are applied for making the transition from stack to building drain acc. to EN 12056 (see drawing). 1 stack 2 building drain

1

2

2 x S 12 07 46/ S 12 11 46

120

25


BRANCH 88.5°

d1/

d2

Code L l1/l

2l3

k1

k2

k3

Qty

56/56 S 20 56 56 175 70 105 30 30 65 20

75/56 S 20 07 56 175 70 105 30 25 65 20

75/75 S 20 07 07 175 70 105 25 25 55 20

110/56 S 20 11 56 225 90 135 45 25 90 10

110/75 S 20 11 07 225 90 135 35 25 85 10

110/110 S 20 11 11 225 90 135 20 20 65 15

160/56 S 20 16 56 * 350 140 210 75 30 145 5

160/75 S 20 16 07 * 350 140 210 80 45 150 5

160/110 S 20 16 11 350 140 210 60 45 135 5

160/160 S 20 16 16 350 140 210 30 35 105 5

200/75 S 20 20 07 * 360 180 180 90 60 90 1

200/110 S 20 20 11 * 360 180 180 70 60 70 1

d1/

d2

Code L l1/l

2l3

k1

k2

k3

Qty

200/160 S 20 20 16 * 360 180 180 45 60 45 1

200/200 S 20 20 20 * 360 180 180 25 60 25 1

250/110 S 20 25 11 * 440 220 220 110 70 110 1

250/160 S 20 25 16 * 440 220 220 85 70 85 1

250/200 S 20 25 20 * 480 240 240 65 40 65 1

250/250 S 20 25 25 * 480 240 240 40 40 40 1

315/110 S 20 31 11 * 560 280 280 170 90 170 1

315/160 S 20 31 16 * 560 280 280 145 90 145 1

315/200 S 20 31 20 * 560 280 280 120 65 120 1

315/250 S 20 31 25 * 560 280 280 95 65 95 1

315/315 S 20 31 31 * 560 280 280 70 65 70 1

* Fabricated

HDPE drainage


DOUBLE BRANCH 45°d

1/ d

2Code L l

1l2

k1 k

2k

3Qty

110/110 S 36 11 11 270 180 100 65 20 20 10

DOUBLE BRANCH 60°d

1/ d

2Code l

1 l

2 Qty

110/110 S 37 11 11 90 102 5

BRANCH 88.5° – SWEPT ENTRYd

1/ d

2Code L l

1 l

2 k

1 k

3Qty

110/110 S 25 11 11 230 140 120 90 20 15

BRANCH 45° – CLEAN OUTd

1/ d

2Code D L l

1 l

2 l

3 k

1 k

3 Qty

110/110 S 33 11 00 140 270 180 195 90 20 55 1

160/110 S 33 16 00 140 375 250 220 125 45 45 1

BRANCH 90°– CLEAN OUTd

1/ d

2Code D L l

1 l

2 l

3 k

1 k

3Qty

56/56 S 23 56 00 83 175 70 100 105 30 65 1

75/75 S 23 07 00 91 175 70 100 105 25 55 1

110/110 S 23 11 20 140 225 90 115 135 20 65 1

160/110 S 23 16 00 140 350 140 140 210 60 135 1

200/110 S 23 20 00 140 360 180 160 180 90 90 1

250/110 S 23 25 00 140 440 220 185 220 110 110 1

315/110 S 23 31 00 140 560 280 220 280 170 170 1

BALL BRANCHES

GENERAL DIMENSIONS 1 DOUBLE BALL BRANCH 88.5° FABRICATED – 90°

2 DOUBLE BALL BRANCH 88.5° FABRICATED – 135°

3 DOUBLE BALL BRANCH 88.5° FABRICATED – 180°

4 TRIPLE BALL BRANCH 88.5° FABRICATED – 90°

1 DOUBLE 90°

2 DOUBLE 135°

3 DOUBLE 180°

4 TRIPLE 90°

5 TRIPLE 135°

6 FOURFOLD 90°

d1/ d

2Code Code Code Code Code Code L l

1 l

2 D k

1 k

2 Qty

110/56 S 24 11 15 S 24 11 25 S 24 11 35 S 34 11 15 S 34 11 25 S 44 11 15 240 120 130 170 30 20 1

110/75 S 24 11 17 S 24 11 27 S 24 11 37 S 34 11 17 S 34 11 27 S 44 11 17 240 120 130 170 30 20 1

110/110 S 24 11 01 S 24 11 02 S 24 11 03 S 34 11 01 S 34 11 02 S 44 11 01 240 120 110 170 30 30 1

5 TRIPLE BALL BRANCH 88.5° FABRICATED – 135°

6 FOURFOLD BALL BRANCH 88.5° FABRICATED – 90°

HDPE drainage



FOUR WAY SOIL MANIFOLDd

1/ d

2Code L L

1L

2L

3L

4k

1k

2Qty

110/56 S 44 11 56 275 162 134 85 136 30 70 1

AERATOR AKAVENTd

1Code L l

1 l

2 l

3 l

4l5

l6

l7

l8

l9

Qty

110 S 60 11 07 * 750 320 170 260 275 90 180 55 130 90 1

160 S 60 16 07 * 715 320 160 235 310 100 200 75 125 110 1

* 1/2/3 = max. Ø 110 mm – 4/5/6 = max. Ø 75 mm Butt-weld only

END CAP – FLATd

1Code D L l

1 Qty

56 S 67 56 07 64 16 12 20

75 S 67 07 07 85 21 16 20

110 S 67 11 07 120 19 19 20

Butt-weld only

END CAP – DOMEDd

1Code L Qty

160 S 67 16 09 45 1

200 S 67 20 09 55 1

250 S 67 25 09 30 1

315 S 67 31 09 30 1

Butt-weld only

56MM BOSS ADAPTERd

1Code Qty

32 S 00 56 32

40 S 00 56 40

Material: TPE

Type A Type B

80

15

15

80

20

20

REDUCER ECCENTRIC – LONGd

1Code L l

1 l

2l3

l4

d3

k1

k2

Qty

200/110 S 14 20 11 * 335 95 36 165 55 160 75 20 1

200/160 S 14 20 16 ** 260 95 95 75 75 1

250/200 S 14 25 20 ** 290 105 95 85 75 1

315/200 S 14 31 20 * 580 115 95 235 190 250 95 75 1315/250 S 14 31 25 ** 340 115 105 75 85 1

* type A ** type B

REDUCER ECCENTRIC – SHORTd

1/d

2Code l

1l2

Qty d1/d

2Code l

1l2

Qty

75/56 S 16 07 56 35 37 20 110/75 S 16 11 07 31 36 20

110/40 S 16 11 04 31 34 10 160/110 S 16 16 11 28 36 5

110/56 S 16 11 56 31 35 10

REDUCER CONCENTRIC d

1Code l

1l2

Qty d1

Code l1

l2

Qty

75/56 S 15 07 56 30 30 20 200/160 S 15 20 16* 50 40 20110/40 S 15 11 04 30 30 20 250/160 S 15 25 16* 60 40 20

110/56 S 15 11 56 30 30 20 250/200 S 15 25 20* 60 50 20

110/75 S 15 11 07 30 30 20 315/200 S 15 31 20* 90 80 20

160/110 S 15 16 11 35 30 1 315/250 S 15 31 25* 90 90 20

*Butt-weld only

CONTRACTION SLEEVEd

1Code L I

1d

xQty d

1Code L I

1d

xQty

50/70 S 55 05 03 210 65 57-64 5 75/90 S 55 07 01 210 75 80-84 5

56/75 S 55 56 01 210 70 62-69 5 110/125 S 55 11 02 210 100 102-111 5

Seal: NBR

STUB FLANGEd

1Code d

1 D L l

1 k

1 Qty d

1Code d

1 D L l

1 k

1 Qty

56 S 47 56 02 * 70 102 60 14 15 5 200 S 47 20 02 * 232 268 100 18 40 1

75 S 47 07 02 * 89 120 50 16 15 5 250 S 47 25 02 * 285 320 100 20 40 1

110 S 47 11 02 125 158 80 18 30 5 315 S 47 31 02 * 335 370 100 20 40 1

160 S 47 16 02 175 210 80 18 30 1 * Butt-weld only

HDPE drainage

25

Ø 5 3

Ø 3 6


d1


WC CONNECTOR 90°d

1/ d Code l

1 l

2 l

3l4

l5 k

1Qty

110/90 S 50 11 85 * 225 76 34 95 17 120 10

110/110 S 50 11 82 ** 225 75 30 92 19 120 10 * Seal: SBR ** Seal: NBR Includes protection plug

WC CONNECTOR 90° – HORIZONTAL

Left

d1/ d Code I

1I

2I

3k

1Qty

110/90 S 50 10 32 * 350 100 75 170 5

110/110 S 50 11 32 ** 350 100 75 170 5 * Seal: SBR ** Seal: NBR Includes protection plug

Right

d1/ d Code I

1I

2I

3k

1Qty

110/90 S 50 10 33 * 350 100 75 170 5

110/110 S 50 11 33 ** 350 100 75 170 5 * Seal: SBR ** Seal: NBR Includes protection plug

DOUBLE WC CONNECTOR 90° – VERTICALd

1/ d Code I

1I

2k

2Qty d

1/ d Code I

1I

2k

2Qty

110/90 S 50 09 34 * 225 275 80 5 110/110 S 50 11 34 ** 185 270 60 5

* Seal: EPDM ** Seal: NBR Includes protection plug

DOUBLE WC CONNECTOR 90° – HORIZONTALd

1/ d Code I

2I

3k

1Qty d

1/ d Code I

1I

2k

2Qty

110/90 S 50 09 35 * 100 275 200 1 110/110 S 50 11 35 ** 100 270 200 1

* Seal: EPDM ** Seal: NBR Includes protection plug

WC CONNECTOR SOCKETd

1Code d D L I

1Qty d

1Code d D L I

1Qty

90 S 50 09 51 * 90 113 49 38 10 110 S 50 11 71 *** 110 130 45 28 10

110 S 50 11 51 ** 90 111 31 20 10

* Seal: SBR ** Seal: EPDM *** Seal: NBR

WC CONNECTOR PROTECTION PLUGd

1Code D D

1 D

2 I

1 Qty d

1Code D D

1 D

2 I

1 Qty

90 S 43 09 19 109 90 103 27.0 50 110 S 43 11 19 130 105 119 23.5 50

ANCHOR BRACKETd

1Code a b s R Qty d

1Code a b s R Qty

56 S 70 56 78 113 30 2.5 “½” 1 200 S 70 20 80 283 40 4 “1” 1

75 S 70 07 78 126 30 2.5 “½” 1 250 S 70 25 80 333 40 4 “1” 1

110 S 70 11 78 161 30 2.5 “½” 1 315 S 70 31 80 398 40 4 “1” 1

160 S 70 16 78 215 30 2.5 “½” 1

Galvanised steel

GUIDE BRACKETd

1Code a b s R Qty d

1Code a b s R Qty

56 S 70 56 10 113 30 2.5 M10 1 110 S 70 11 10 161 30 2.5 M10 1

75 S 70 07 10 126 30 2.5 M10 1 160 S 70 16 10 215 30 2.5 M10 1

Galvanised steel

MOUNTING PLATECode R I

1I

2I

3I

4S C Qty

S 70 94 78 * ½” 145 38 90 25 4 8,5 1

S 70 94 10 ** M10 145 38 90 14 4 8,5 1

S 70 94 80 ** 1” 145 38 90 25 4 8,5 1

Galvanised steel

PIPE SCRAPERCode Qty

S 41 96 00 1

360

98

Available in black only, with the exception of protection plug (white) and brackets & mounting plate, which are manufactured from galvanised steel.

HDPE drainage

1716 MARLEY HDPE || MARLEY HDPE

HDPE installation

Tempered Pipe

Compatibility

Bends at the base of vertical stacks should be of long radius and have a minimum centre line of 200mm on a 100mm nominal size stack. Two 45° bends may also be used as an alternative to provide the change of direction. The same design principle should also be adopted where offsets occur in stacks that have more than one storey height above the offset.

S411195 Electrofusion coupling

2No S121146 Long spigot bend 45°

S005632/S005640 32/40mm rubber boss adaptor

S201156 56mm Boss pipe

P040 'P' trap

40mm PVC-c/ABS waste pipe

S005640 rubber boss adaptor

56mm HDPE

B032R Resealing bottle trap

32mm PVC-c/ABS waste pipe

S005632 rubber boss adaptor

56mm HDPE

Shrinkage according to EN 1519 (3%)

Maximum shrinkage tempered Akatherm pipe (1%)

Pipe length after production

AbbreviationD External dimension fitting partd1, d2 ... External dimension fitting/pipee Wall thicknessk1,k2 ... Maximum length for shortening fittingsL Total length fittingl1,l2 ... Lengths of part of fittingTPE Thermoplastic ElastomerSBR Styrol butadiene rubberNBR Acrylnitril-butadiene rubberEDPM Ethylene propylene copolymerHDPE High density polethylene

Marley HDPE pipe is tempered. This pipe is produced according to the standards EN 1519 and ISO 8770 and has undergone a heat treatment after extrusion. The result is less shrinkage when cooled down from high operational temperature. This gives less stress on joints resulting in a longer life for the pipe system.

Linear expansionMarley HDPE material has a linear expansion coefficient of 0.13-0.19 mm/mK. We calculate with an expansion of 0.2mm per meter pipe for every °C temperature difference. The total length variation can be calculated as follows:

Δl = L x λ x ΔtΔl = length change in mm L = total length of pipeλ = linear expansion coefficientΔt = temperature difference in °C

Example:

10 metres of pipe with a maximum temperature of 60°C and a minimum temperature of -20°C. This results in an expansion of:

Δl = 10 x 0,2 x 80 = 160 mm

Length changes can be accommodated by the expansion socket which can take up the expansion and contraction of a 5 meter length of pipe for temperatures between -20°C and 70°C.

ElectrofusionMarley HDPE products can be welded by electrofusion unless stated differently in the product table. This is the preferred method of on-site jointing.

Butt welding and k-dimensionMarley HDPE products can be welded using this jointing method. Fittings can be shortened by up to the k-dimension (indicated in the product specification section page, 6–15), still allowing butt-welding on a standard butt-welding machine.

The Marley HDPE range can be connected to PVC-c or ABS materials, allowing for easy waste pipe connection to the discharge stack.

Soil stack:Connection from a 56mm boss pipe to a 32mm or 40mm pipe, using a 56m rubber boss adaptor.

Bottle traps:32mm and 40mm rubber boss pipe connections to bottle traps.

Butt-weld plugin socket

S251

111

S251

111

S251

111

S201

156

S201

156

S201

156

S425650

S421150 S421120S411195 S411195

S101100 or

S101103

S101100 or

S101103

S101100 or

S101103

S101100 or

S101103

50mm PVC 50mm PVC 50mm PVC

110mm PVC 110mm PVC 110mm PVCSE405

KEC3S105600S405620

S415695S415695

Electrofusion coupling with expansion socket

Pvc coupling pushfit to HDPE

Alternative connectors:Alternative connections from HDPE to PVC-u and PVC-c.

Bends at the base of stacks

Abbreviations

Testing the systemThe system should be inspected for any possible leaks in accordance with BS EN 12056. Air should be pumped into the system through a branch of a tee piece until a pressure equal to 38mm water gauge is achieved. The inlet valve should then be closed and the system should maintain the pressure for a minimum of three minutes.

Chemical resistanceFor all chemical resistance enquiries please contact our technical support team on 01622 852695.


HDPE jointing methods

Electrofusion, the most simple and rapid jointing technique, for a highly efficient method of assembly for pipes, fittings and prefabricated sections.

Electrofusion couplersThe HDPE range includes couplers in a range of core diameters up to 315mm. The couplers are extremely suitable for applications in waste water and rainwater drainage, with the following features:

1. Injection moulded with excellent dimensional accuracy and stability.

2. Welding indicators on each welding surface for visual identification to show that the coupler has been welded.

3. Centre stops easy to remove, in order to use the coupler as a slide- over coupler.

4. Resistance wires fixed to the surface for an optimal heat transfer and therefore a high quality welding connection.

5. Yellow edge surrounding the welding indicators of the diameters 200, 250 and 315mm are provided for better visibility.

Correct Jointing procedure

1. Cut the pipe square

The pipe ends must be cut square to ensure that the heating element in the coupler is completely covered by the pipe or fitting.

✔

2. Mark insertion depth + 10 mm

This is to ensure that across the full welding zone the oxidised layer will be removed.

✔

3. Scrape pipe and mark insertion depth again

The outer surface of the pipe (approx. 0.2mm deep) must be scraped for the full distance that will be covered by the coupler to remove any surface 'oxidation'.

The insertion depth should be marked again to safeguard full insertion.

✔

4. Clean coupler

Before assembling the pipes into the coupler ensure that all surfaces are clean and dry.

✔

5. Insert pipe and/or fitting up to pipe stop

Ensure that the pipe is pushed as straight as possible into the fitting.

✔

Incorrect Jointing procedure

1. Prevent misalignment

✗

2. Prevent coupler from sliding down when installed vertical

✗

3. Don't weld coupler twice

✗

4. Prevent load on vertical pipesystem

✗

After connecting the cables of the control box the welding process can commence by pushing the start button. The control box adapts the welding time to the ambient temperature. When it is colder than 20°C the welding time is extended and when the ambient temperature exceeds 20°C the welding time is shortened. For welding times and cooling down time see table below.

The joint assembly should not be disturbed during the fusion cycle and for the specified cooling time afterwards.

dimension d1

systemweld time

cooling time

mm sec min

40-160 Constant current 5A 80 20

200-315 Constant voltage 220V 420 30

Butt-welding is a very economical and reliable jointing technique for making welded joints, requiring only butt-welding equipment. All pipes and fittings can be joined by this welding method. Fittings for which a k-dimension is shown in the product section, (page 6–15), can be shortened by not more than this amount. Butt-welding is extremely suitable for prefabricating pipe sections and for making special fittings.

Preparations

The following guidelines are of importance when making a proper butt-weld:

● Establish a work space where the jointing can be done without being effected by major weather conditions.

● Check the equipment functions properly. Welding equipment used on site deserves special attention.

● The fittings and or pipes need to be aligned in the welding machine. Mis-alignment can be up to 10% of the wall thickness.

● Clean the heating element before each jointing operation with a lint- free cloth and suitable cleaner (see instructions supplied with the welding machine).

● Cut the pipe and/or fitting with a pipe cutter to make the end square.

● Make sure that once the pipe and/or fitting ends have been machined, they do not get dirty. Do not touch them with your hands. The surface needs to be clear of oil, grease and dirt.

● Put the pipe parts into the welding machine to facilitate a firm hold during the jointing process.

● A digital thermometer can be used to check the temperature of the heating plate. The temperature should be checked at several points around the plate and should be between 200ºC and 220ºC. Maximum deviation between points is given in the table.

Used surface of heating element for welding diameter (d

1)

Δt max

d1 = 40-160 8ºC

d1 = 200-315 10ºC

Maximum temperature variation heating element

10 mm

10 mm

10 mm

10 mm

10 mm

42

KG

2x

42

KG

2x

42

KG

2x

Electrofusion Butt-welding

42

KG

2x

10 mm

10 mm

10 mm



The butt-welding of Marley HDPE operates according to the following steps:

Machining the surfaceBoth sides should be machined until they run parallel. When the machining is finished, open the carriages (the plastic shavings must be continuous and uniform in both sides to weld). Take off the milling cutter.

Verify the alignment between the machined surfaces. Remove the plastic shaving. Do not touch or get any dirt on the machined surfaces.

Preheating under pressurePress the two ends to be jointed gradually on to the heating element until a bead is created. The size of the bead is a good indication that the appropriate pressure and time is used. For pressure and bead size see the table on the next page.

Diameter d

1

Wall thickness e

Preheating pressure / welding pressure

(0,15 N/mm2)

Heating pressure

(0,01 N/mm2)Height

welding bead Heating timeChangeover

timeBuilding-up

pressure time Cooling time

mm mm FO/FL N Fd N mm sec sec sec min

*40 3.0 55 4 0.2 29 4 4 4*50 3.0 70 5 0.5 30 4 4 4

56 3.0 75 5 0.5 30 4 4 4

*63 3.0 85 6 0.5 31 4 4 4

75 3.0 105 7 0.5 32 5 5 4

*90 3.5 145 10 0.5 35 5 5 4

110 4.2 210 14 0.5 42 5 5 6

*125 4.8 275 18 1.0 48 5 5 6

*125 3.9 225 15 0.5 39 5 5 5

160 6.2 450 30 1.0 62 6 6 9

110 3.4 175 12 0.5 35 5 5 4

160 4.9 370 25 1.0 49 5 5 7

200 6.2 570 38 1.0 62 6 6 9

250 7.8 900 60 1.5 77 6 6 11

315 9.7 1400 93 1.5 77 6 6 11

200 7.7 700 47 1.5 77 6 6 11

250 9.6 1090 73 1.5 97 7 7 13

315 12.1 1730 115 2.0 121 6 8 16

Marley HDPE – Welding parameters

In this table the welding parameters can be found for Marley HDPE. The exact regulation of the welding machine depends on its mechanical resistance. The tables provided with the machine are to be used for regulating the machine.

(PE)

0,15

0,01

preheating pressure (Fo)

pressure N/mm2

heating pressure (Fd)

welding pressure (FL)

preheating time heating time

total time welding process

cooling time

total welding time

time

build

ing-

uppr

essu

re ti

me

chan

geov

ertim

e

height welding bead

HDPE

Welding process

*Please note these sizes are made to order and require a 28 day lead time.

Heating up with less pressureHDPE is a good insulator, therefore at this stage it is necessary that the correct heating depth of the pipe ends is obtained. Only a small amount of pressure 0.01 N/mm2 is required to maintain the contact of the pipe ends with the heating element. The heat will gradually spread through the pipe/fitting end. The size of the bead will increase a little. The time and pressure needed for this phase can be found in the table on the next page.

Change overRemove the heating element from the jointing areas and immediately make those areas touch each other. Do not push the pipe ends abruptly onto each other.

The removal of the heating element needs to be done quickly to prevent the pipe ends from cooling down. The times for changing over can be found in the table on the next page.

Welding and coolingAfter the jointing areas have made contact they should be joined with a gradual increase in pressure up to the specified value. Keep the specified welding pressure at a constant level during the cooling period. Do not cool artificially.

The welded components can be removed from the machine when 50% of the cooling period has elapsed, providing that this is done carefully, with no load or strain being placed on the joint. The joint must then be left undisturbed for the remainder of the cooling period.



The butt-weld can be evaluated using destructive and non destructive evaluation methods. For these evaluations special equipment has to be used. Butt-welds can easily be judged by a visual inspection making this the recommended method for a first evaluation.

The shape of the welding bead is an indication for the proper operation of the welding process. Both welding beads should have the same shape and size. The width of the welding bead should approximately be 0.5 x the height. Differences between the beads can be caused by the difference in HDPE material used in the welded components. Despite the differences in welding bead the butt can be of sufficient strength.

In the next illustration a good weld is shown with a uniform welding bead. At a visual inspection this would be classified as an "acceptable" weld.

Butt-weld with even welding beads (acceptable)

✔

Mis-alignment between fittings and pipe can occur for several reasons. Oval pipe ends or irregular necking of the pipe can cause an incomplete fit. If this is less than 10% of the wall thickness the weld can still be classified as "acceptable" (see next illustration).

Butt-weld with mis-alignment of pipe (acceptable)

✔

The next illustration shows a joint with beads that are too big. The uniformity indicates a good joint preparation. Heat supply and jointing pressure settings, however, are too high. A purely visual assessment would still classify the weld as "acceptable".

Butt-weld with big welding beads (acceptable)

✔

When there is either insufficient heating up or too low welding pressure there are hardly any beads. In cases like this thick walled pipes often form shrinking cavities. The weld must be classified as "not acceptable".

Butt-weld (not acceptable)

✗

In the next illustration a cross-section of a regular, round fusion bead, free of notches or sagging is shown. Special attention should be paid to the fact that the collar value 'K' is greater than 0.

Cross section of a good butt-weld

✔

A plug-in joint is an easy to make, detachable and non pull-tight jointing method.

Jointing process:

Cut pipe square and remove burr

✔

Mark insertion depth

✔Plug in socket:

The pipe needs to be inserted in the plug in socket using the full insertion depth.

A plug-in joint is not to be used to accommodate the expansion and contraction of a pipe system.

Chamfer pipe end

✔The pipe-end needs to be chamfered at an angle of 15°. To obtain an even cut and chamfer a chamfering tool should be used.

Make jointLubricate the pipe end and insert the pipe up to the marked insertion depth.

Expansion sockets can absorb length changes of pipes with a maximum length of 5 m.

Jointing process:

Cut pipe square and remove burr

✔

Mark insertion depth

✔An expansion socket counteracts the variation in length caused by the thermal expansion and shrinkage of the pipe.

Depending on the ambient temperature the insertion depth varies. The right insertion depth for both 0°C and 20°C is indicated on the expansion socket.

Chamfer pipe end

✔The pipe-end needs to be chamfered at an angle of 15°. To obtain an even cut and chamfer a chamfering tool should be used.

Make jointLubricate the pipe end and insert the pipe up to the marked insertion depth.

Evaluating the butt-weld joint Plug-in joint Expansion joint

max 0.1 e*

e*

* For the value of 'e' please refer to the table on page 21


HDPE bracketing

The bracket distances for Marley HDPE pipes are largely dependent on the working temperature of the pipe system. Also the filling rate of the pipe plays a role. A fully filled pipe has a different bracket distance.

Bracket distances for vertical and horizontal PE pipe systems with standard filling

Horizontal installation with expansion socketsThe bracket directly in front of the expansion socket has a shorter bracket distance (LA*) This makes a better guidance into the expansion socket possible (see image). The bracketing distances for this application can be found in table below. The maximum distance between 2 expansion sockets is 5 m.

d1

LA LA*

75 0.8 m 0.4 m

*90 0.9 m 0.5 m

110 1.1 m 0.6 m

*125 1.3 m 0.7 m

160 1.6 m 0.8 m

200 2.0 m 1.0 m

250 2.0 m 1.0 m

315 2.0 m 1.0 m

Bracket distances horizontal installation with expansion sockets *Please note these sizes are made to order and require a 28 day lead time.

Bracket distanceBracketing system

For the installation of Marley HDPE pipe systems several bracketing systems can be used:

Anchor point bracketThis method of bracketing is used for rigid installations. The expansion forces are transferred to the building structure.

Anchor bracket with expansion socketThis method of installation is used for flexible installations where the expansion force is not transferred to the building structure. Only the force caused by the internal resistance of the expansion socket is transferred.

Guide bracketThe guide bracket is used to support the pipe and to prevent the pipe from buckling sideways when in a rigid installation. The pipe can freely move in the bracket.

Support bracket fixed to building structure- brackets must be of sufficient strength to resist forces generated by thermal movement of the pipes

Electrofusion coupler either side of support bracket

Support bracket fixed to building structure-brackets to be of sufficient strength to resist forces caused by the internal resistance of the expansion socket

Thermal movement of PE pipework


HDPE handling and storage

FittingsThe fittings and electrofusion couplers need to be stored in a dry place. To prevent oxidation and contamination, it is recommended to leave the fittings in their original packaging as long as possible.

PipesThe high impact strength of Marley HDPE provides some protection against damage but care should be taken at all stages of handling, transportation and storage.

Pipe must be transported by a suitable vehicle and properly loaded and unloaded, e.g. wherever possible moved by hand or mechanical lifting equipment. It must not be dragged across the ground. The storage should be flat, level and free from sharp stones.

BundlesBundled packs of pipe should be stored on clear, level ground with the battens supported from the outside by timber or concrete blocks. For safety, bundled packs should not be stacked more than three high.

Smaller pipes may be nested inside larger pipes. Side bracing should be provided to prevent stack collapse.

Similar precautions should be taken with fittings and these should be kept packaged until required for use.

Storage of bundles

LengthsPipe lengths stored individually should be stacked in a pyramid not more that one metre high, with the bottom layer fully restrained by wedges. Where possible, the bottom layer of pipes should be laid on timber battens at one-metre centres. On site, pipes may be laid out individually in strings (where appropriate, protective barriers should be placed with adequate warning signs and lamps).

Storage of loose pipes

ToolsTools need to be protected against moisture.

Health and safety at work act and COSHH regulationsAttention is drawn to the requirement in the UK of this act and to the 1988 Control of Substances Hazardous to Health (COSHH) Regulations. Marley cannot accept responsibility for accidents arising from the misuse of its products because of bad installation or incorrect application.

Handling of HDPE has no detrimental health impact. It is recommended, however, that HDPE is not ingested or dust inhaled.

Personal Protective Equipment (PPE)When welding HDPE, molten material is formed, which can cause burns to skin. Appropriated PPE should be worn.

Physical contactHDPE is not considered to be a skin irritant. Where HDPE dust is generated by cutting of machining pipe of fittings, powder particles of HDPE dust may cause eye irritation by abrasion.

Behaviour in FireHDPE is a flammable material. It has, however, been installed throughout Europe for over 35 years and presents no greater risk of fire propogation than similar plastic based systems when installed in accordance with local regulations. Marley offer a range of firecollars suitable for HDPE. Please speak to our Technical Department on 01622 852695 for further information.

Vertical installation: to the wallFor the vertical installation the bracketing distance is in general 1,5 times the distance of the horizontal bracketing. There is no separate bracketing distance for immediately in front of the expansion socket because there is no sagging of the pipe and the insertion is always in line.

Vertical installation

GB = guide bracket FP = fixed pointLV = vertical support distance

d1 LV

*50 1.0 m

56 1.0 m

*63 1.0 m

75 1.2 m

*90 1.4 m

110 1.7 m

*125 1.9 m

160 2.4 m

200 3.0 m

250 3.0 m

315 3.0 m

Bracket distances vertical installation with expansion sockets


HDPE Expansion Details

Type A

(No White Retaining Ring)

Type B

(With White Retaining Ring)Diameter Total LengthMin. Insertion Depth @ 20°C

Max. Expansion

*40mm 132mm 76mm 56mm Type B


56mm 132mm 76mm 56mm Type B


*75mm – On Fitting On Fitting Type A

*90mm – On Fitting On Fitting Type A

110mm – On Fitting On Fitting Type A



200mm 230mm 120mm 110mm Type A




HDPE expansion socket insertion depth

Bracket distance


Standards Marley system solutions

Accreditations

Marley PVCu Soil Standard PVCu soil systems to BS EN 1329: 2000. Ideal for domestic and commercial applications, including branch connections to other materials. Available in 82mm, 110mm and 160mm, ring seal and solvent weld jointing variants.

Marley waste systems A wide range of PVC-u, ABS and polypropylene waste ranges from 32mm to 50mm and in a variety of colours. Available in solvent weld and push fit jointing.

Marley acoustic An acoustic soil and waste range with a layered pipe providing quick, hygienic removal of sanitary waste water. The noise generated by the flow of water is dramatically reduced – making it perfect for multi-occupancy apartment blocks and high specification developments.

Marley rainwater Five gutter profiles and three downpipe options provide a rainwater solution for any application. Advanced Life4 technology on four of the key profiles, coupled with the benefits of the Easyclip and notching capability combine to make the Marley rainwater range the most comprehensive available.

Marley underground systems The Marley Plumbing & Drainage range of underground systems include the solid wall range, predominately for round the house drainage and Quantum structured wall range for sewer and highway drainage applications.

Alutec Alutec offer modern and traditional aluminium rainwater profiles, providing solutions for any type of building. Aluminium has high visual appeal and durability, lasting for 50 years or more. The product portfolio includes Evolve; easy to install, low cost gutter systems in four profiles. The rainwater ranges are complemented by aluminium soffit and fascia systems and roof & floor outlets.

BS EN 1519-1: 2000Plastics piping systems for soil and waste discharge (low and high temperature) within the building structure – polyethylene.

BS EN ISO 9001: 2008Quality systems. Model for Quality Assurance in Design, Development, Production, Installation and Servicing.

BS EN ISO 14001: 2004Environmental management systems. Requirements with guidance for use.

NOTE:Marley Plumbing & Drainage products are manufactured to a constant high standard. The Company will not therefore accept responsibility for failure of any installation which includes components not supplied by us.

Customer attention is drawn to the Company’s official Terms and Conditions of Sale. Goods are supplied strictly in accordance with these terms and conditions, copies of which are freely available on request and on marleypd.co.uk. Product illustrations may vary slightly depending on the type and size. Product images are for illustrative purposes only. Qty, refers to the pack quantity. Products can be purchased individually e & o e.

FM 30637 KM 545820EMS 96207BS EN 1519

British & European Standards

Underground

30 | MARLEY HDPE

marleypd.co.uk For general enquiries and details of your nearest stockist please call the customer services department: Tel: 01622 852585Email: [email protected]

To place an order

For delivery to England & WalesEmail: [email protected]: 01622 851111For delivery to ScotlandEmail: [email protected]: 01698 810307

For all estimate requestsEmail: [email protected]

For Technical advice please call 01622 852695

Head OfficeLenham, Maidstone Kent ME17 2DE Tel: 01622 858888 Fax: 01622 858725

Email: [email protected]

ScotlandBirkenshaw Industrial Estate Uddingston, Glasgow G71 5PA Tel: 01698 815231 Fax: 01698 810307

Export DivisionLenham, Maidstone Kent ME17 2DE England Tel: +44 (0)1622 858888 Fax: +44 (0)1622 850778

Email: [email protected]

April 2015

@marleyplumbing

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